Catalytic alloy material and catalytic device containing the same

ABSTRACT

This invention relates to an emission control device containing a catalytic material capable of reducing pollutants in the combustion gases generated from an internal combustion engine, as well as from other combusted solid and liquid fossil fuels such as coal, and is also useful for treating combustion gases generated from the incineration of landfill garbage and tire rubber, among others. The catalytic material of the present invention is highly resistant to deactivation or poisoning from contaminants in the combusted material such as leaded gasoline. The catalytic material predominantly comprises a plagioclase feldspar belonging mainly to the albite-anorthite series and contains small amounts of mica, kaolinite and serpentine, and optionally contains magnetite. A catalytic alloy material is also disclosed, comprising a mixture of the above-described catalytic material and a metal. The alloy material likewise exhibits unique catalytic properties.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation-in-part application of my prior U.S. applicationSer. No. 07/783,877 filed Oct. 29, 1991 and now U.S. Pat. No. 5,288,674.

FIELD OF THE INVENTION

The invention relates to a catalytic device for treating combustion gaspollutants with use of a catalytic material derived from an unusualmineral formation of volcanic ash in either its native state, aspreconditioned by magnetic separation, or as an alloy. Moreparticularly, the invention relates to a catalytic material suitable fora variety of applications including, but not limited to, (1) treatmentof exhaust gases generated by combustion of fossil fuels, both liquidand solid, and wood materials; and (2) treatment of gases generated fromincineration of tire rubber and landfill waste; and also (3) scrubbingof steam well gases. The catalytic material of the present inventiondisplays a remarkable ability to reduce the proportion of exhaust gaspollutants such as hydrocarbons, carbon dioxide, carbon monoxide, sulfurdioxide, nitrogen oxides while increasing oxygen output and stronglyresisting deactivation by catalytic poisons.

BACKGROUND OF THE INVENTION

It is well known that the combustion of fossil fuels, e.g., gasoline,generates deleterious automobile exhaust containing carbon monoxide,carbon dioxide, oxides of nitrogen (primarily NO_(x)), water, andnitrogen. The exhaust also can contain a wide variety of hydrocarbonsand also particulates including carbon and oxidized carbon compounds,metal oxides, oil additives, fuel additives, and breakdown products ofthe exhaust system, including the exhaust-control catalysts.

These exhaust products can combine in a large variety of ways in theatmosphere, particularly since the amounts of each material change withoperating conditions and the mechanical state of the vehicle. Thephotochemical reaction between oxides of nitrogen (NO_(x)) andhydrocarbons (HC) that caused the original interest in the automobile asa source of pollution has been investigated extensively.

Due to the now well-appreciated harmful effects of the vehicle emissionpollutants to both health and to the environment in general, everincreasing stringent air quality standards are being imposed onemissions at both a federal and state level.

Also, many commercial operations, industrial processes or even homeheating systems generate noxious gaseous chemical by-products, theremoval of which must comply with federal or state regulations. Theseregulations may be highly expensive to meet with, if not costprohibitive, using current exhaust gas treatment technology. Therefore,the anticipated benefits of improved environmental quality confers avery high value on any new engineering technology that might be usefulto meet the regulatory air quality standards.

A known technology for control of exhaust gas pollutants from bothstationary and mobile sources is their catalyzed conversion into moreinnocuous chemical species. Conventional oxidation catalysts used inthis regard promote further burning of hydrocarbons and carbon monoxidein the exhaust gas. The normal operating temperature is 480° to 650° C.Oxidation catalysts in current use normally start oxidizing within twominutes after the start of a cold engine and will operate only when thecatalytic species is sufficiently heated to achieve an activationtemperature.

Known oxidation catalysts consist of platinum and mixtures of platinumand other noble metals, notably palladium. These metals are deposited onalumina of high surface area. The alumina ceramic material is typicallycapable of withstanding very high temperatures. The ceramic core hasthousands of passages--about 240 per square inch. These passages presentan enormous surface area for contact with the exhaust as it passesthrough the catalytic converter. The ceramic passages are coated withthe platinum and palladium metals. These metals provide the catalysts.

When properly contained in the muffler-like shell of the catalyticconverter, the catalysts will reduce hydrocarbon and carbon monoxidepollutants by changing them into more harmless products of water vaporand carbon dioxide. Another common form of oxidization catalyst involvesa monolith in a honeycomb configuration to provide the necessary surfacearea and a top layer of the deposited catalytic metal species. Theselection of one or the other above catalytic configurations is dictatedby the kind of vehicle usage, as understood in the field.

However, conventional catalytic devices and catalytic species usedtherein have serious drawbacks in that they typically are susceptible topoisoning, i.e., deactivation resulting from chemical changes caused bythe combined effects of thermal conditions and contamination ascharacterized by a chemical reaction of a contaminant with the supportedcatalysts. For instance, the most notorious poison for vehicularcatalytic converters is the lead compound used as an anti-knockingagent. The poisoning of the catalysts by the contaminant, such as lead,is irreversible.

Moreover, many conventional catalysts also are susceptible toinhibition, or so-called reversible poisoning because of its temporaryeffect, due to exposure of the catalytic species to many common exhaustgas components such as carbon monoxide, nitrogen oxides or even somereduced sulfur compounds.

Compounding the poisoning problem encountered with many conventionalcatalysts used in treatment of exhaust gases is the demand for a moreversatile catalytic species having applicability to diverse areas ofexhaust gas treatment.

For instance, the federal and state regulatory attitude is everincreasingly stricter in imposing emission control standards covering aplethora of both commercial and private emission sources, e.g., coalburning plants and stoves, wood burning stoves, garbage incineration,used tire incineration, and not merely vehicle exhaust regulation.

Therefore, in an effort to meet current and perhaps even stricter futureenvironmental air quality objectives, many public and private concernshave urgently awaited any possible innovations in the catalytic exhaustcontrol field which might meet these standards.

SUMMARY OF THE INVENTION

One of the objects of the present invention is to provide an emissioncontrol device containing a catalytic material capable of reducing thelevel of harmful pollutants contained in exhaust gases generated by thecombustion of fossil fuels, wood materials, rubber materials and thelike.

It is another object of the present invention to provide a catalyticmaterial which is not only capable of reducing the hydrocarbon, carbonmonoxide and carbon dioxide emissions from burnt fossil fuels, but whichalso can reduce NO_(x) emissions while concomitantly increasing theoxygen (O₂) content of the catalytically treated exhaust.

It is still another object of the present invention to provide animproved catalytic material which is highly resistant to poisoning fromexhaust contaminants and has versatility in treating a wide diversity ofcombustion gas material generated from, for example, solid and liquidfossil fuels, other carbonaceous materials such as wood and garbage, aswell as used tire rubber.

It is yet another object of the present invention to provide a catalyticmaterial useful for scrubbing of steam well gases.

Towards achieving the above and other objects of the present invention,this invention provides for a novel catalytic material obtained from avolcanic ash material located in northern Nevada, Washoe County, nearPyramid Lake.

The inventive material comprises predominantly, i.e., greater than 50%by weight, plagioclase feldspar. Plagioclase is a general name fortriclinic feldspars having anorthic or asymmetric crystal structure ofthree unequal long axes at oblique angles. Feldspar comprises themineral K₂ O,Al₂ O₃,6SiO₂.

Moreover, the predominant mineral component, plagioclase feldspar,belongs to the albite-anorthite series; in other words, the feldsparmaterial itself comprises albite and anorthite minerals. The albite(NaAlSi₃ O₈) and anorthite (CaAl₂ Si₂ O₈) minerals are completelycompatible and together form an isomorphous series ranging from the puresoda feldspar at the one end to the pure lime feldspar at the other endof the isomorphous series. There are isomorphous relations between thesetwo molecules and substantial identity of crystal structure. Forexample, the sodium and calcium atoms, on one hand, and the silica andaluminum atoms, on the other, may replace each other in the structure.

Additionally, the inventive material contains minor amounts of otherminerals, which, in sum, comprise less than 50% by weight of the totalweight of the inventive material. Among the minerals which mayconstitute the "minor components" of the material and which have beenidentified as mica are--KAl₂ Si₃ AlO₁₀ (OH)₂, kaolinite--H₄ Al₂ Si₂ O₉or 2H₂ O.Al₂ O₃.2Si₂ and serpentine--H₄ MgSi₂ O₉ or 3MgO.2SiO₂.2H₂ O.These minerals are considered to constitute the bulk of the minorcomponents, but the material obviously may contain a variety of otherimpurities, i.e., small amounts of other minerals and trace amounts ofvarious metals and other elements. In its native state, the materialalso contains magnetite (FeO.Fe₂ O₃).

While it has been discovered that the inventive material of the presentinvention can exhibit the catalytic effect in its native state, it hasfurther been discovered that the catalytic effect can be enhanced whenthe inventive material is subjected to a magnetic separation treatmentto remove magnetite (Fe₃ O₄ or FeO.Fe₂ O₃).

The inventive material may also be combined with a metal to form acatalytic alloy material. The catalytic alloy material likewise exhibitsunique catalytic properties, as described herein.

The novel features which are considered as characteristic for theinvention are set forth in particular in the appended claims. Theinvention itself, however, both as to its construction and its method ofoperation, together with additional objects and advantages thereof, willbe better understood from the following description as specificembodiments when read in connection with accompanying drawings.

Also, while the precepts of the present invention are presented in thecontext of an emission control device inserted into the output of anexhaust manifold of an internal combustion engine, it is to beunderstood that the inventive material and principles of its usedescribed herein are adaptable to many other types of combustion gastreatment units.

BRIEF DESCRIPTION OF DRAWING

FIG. 1 represents a perspective view of an emission control devicecontaining the catalytic material of the present invention when insertedinto the output manifold of an internal combustion engine.

FIG. 2 depicts a perspective view of an emission control devicecontaining the catalytic material of the present invention when insertedinto the exhaust pipe of a two-cycle engine pulse air system.

FIG. 3 shows a perspective view of an internal combustion engine, suchas a 4-, 6- or 8-cylinder engine, showing various usages of thecatalytic material of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

In the present invention, a catalytic material is used which is avolcanic ash obtained from an unusual mineral formation located innorthern Nevada, Washoe County, near Pyramid Lake.

While the igneous raw mineral used in the present invention is availablein different forms, two exemplary types of the material include thefollowing: (1) a mineral substance which is light beige in color andresembles a sandstone type of material or texture, and (2) a mineralsubstance which is black in color and resembles a basalt type ofmaterial.

Based on expert interpretations of X-ray studies and other elementalanalyses performed on the inventive material, both of theabove-described strains of the inventive material are principallyconstituted by plagioclase feldspar and possess a complex morphology andesoteric composition.

The predominant (i.e., greater than 50 weight %) mineral component,plagioclase feldspar, is considered to belong to the albite-anorthiteseries. The albite (NaAlSi₃ O₈) and anorthite (CaAl₂ Si₂ O₈) mineralsare completely compatible in terms of their crystal structure, andtogether form an isomorphous series ranging from the pure soda feldsparat the one end to the pure lime feldspar at the other end of the series.There are isomorphous relations between these two molecules andsubstantial identity of crystal structure. The sodium and calcium atoms,on one hand, and the silica and aluminum atoms, on the other, mayreplace each other in the structure.

Also, as noted above, other minerals may be present in the material inamounts of up to (in sum total) 50% by weight, including, but notnecessarily limited to, minor amounts of mica--KAl₂ Si₃ AlO₁₀ (OH)₂,kaolinite--H₄ Al₂ Si₂ O₉ or 2H₂ O.Al₂ O₃.2Si₂ and serpentine--H₄ MgSi₂O₉ or 3MgO.2SiO₂.2H₂ O. However, as noted above, a variety of impurities(other minerals, trace amounts of metals and other elements) are alsopresent, including magnetite.

ICP (Inductively Coupled Plasma) and AA (Atomic Absorption) analyseswere performed on the inventive material under the following protocol.The inventive material, as obtained from the source location describedherein, was ground and homogenized by means of a disk disintegrator inorder to obtain fraction of less than 100 mesh. Certain samples from theground material were subjected to magnetic separation (i.e., removal ofmagnetite) and then treatment at temperatures of 500° C. (932° F.) or750° C. (1382° F.) for two hours. The testing samples were numbered asfollows:

1. Original inventive material (clumps removed by mechanical grinding).

2. Inventive material after magnetic separation.

3. Magnetic fraction isolated from the original inventive material.

4. Inventive material after magnetic separation and after treatment at500° C.

5. Inventive material after magnetic separation and treatment at 750° C.

Samples 1, 2, and 3 were then digested in acids using the followingprocedure:

1 gram of a sample was placed in teflon beaker and added 15 ml nitricacid (HNO₃), 10 ml percloric acid (HClO) and 2 ml hydrofluoric acid(HF). That beaker was covered with teflon lid and placed on a 250° F.hotplate for 11/2 hours. Then the cover was removed and mixtures wereevaporated at 300° F. for 4 hours. The residue in the beaker was cooledand added 5 ml HNO₃ and 20 ml distilled water. The mixture was boiledfor 5 minutes and diluted to 50 ml in volumetric flask with distilledwater. That solution was analyzed for metal (but not Si/silicacontent--see below) content by means of Inductively Coupled Plasma (ICP)using Perkin-Elmer Plasma II Emiston Spectrometer and by means of AtomicAbsorption Spectrometer using Perkin-Elmer AAS-3100. The results fromthese analyses are shown in Table 1.

                                      TABLE 1                                     __________________________________________________________________________    "ICP" AND "AA" ANALYSIS OF MATERIAL IN PPM                                    __________________________________________________________________________    Sample                                                                        Number                                                                             Zn  Cd                                                                              Pb Cu  Co  Ni  Fe   Mn   Y Mg Ca                                   __________________________________________________________________________    1    50  10                                                                              30 10   0  0   21500                                                                              475  10                                                                              3715                                                                             14740                                2    45   0                                                                              35 10   0  0   11000                                                                              340  10                                                                              3440                                                                             15585                                3    840 40                                                                              80 40   45 0   507000                                                                             3875 20                                                                               375                                                                             11235                                __________________________________________________________________________    Sample                                                                        Number                                                                             Mo  W B  Ba  P   Nb  Ti   As   Cr                                                                              Sb Ta                                   __________________________________________________________________________    1    0   10                                                                              40 1100                                                                              385 15   1325                                                                              10    0                                                                               10                                                                                15                                 2    0    0                                                                              35 1110                                                                              300 15   1325                                                                              10    0                                                                                0                                                                                20                                 3    0   20                                                                              35 210 3115                                                                              175  1300                                                                              40   30                                                                               50                                                                               105                                 __________________________________________________________________________     Sample                                                                       Number                                                                             Bi  Be                                                                              V  Zr          Na   K         Al                                   __________________________________________________________________________    1    0    0                                                                              30 75          30300                                                                              26500     111740                               2    0    0                                                                              10 75          30200                                                                              26100     105220                               3    10  10                                                                              845                                                                              40           4010                                                                              2800      10460                                __________________________________________________________________________

To determine the SiO₂ content from samples 1, 2 and 3, the samples werealso subjected to high pressure digestion in hydrofluoric acid in orderto dissolve the materials. The samples were then analyzed as above, andSiO₂ content was found to be 66.3 wt % for sample 1, 67.1 wt % forsample 2, and 11.7 wt % for the magnetic fraction, sample 3. Overall,these elemental analyses of samples 1 and 2 confirm the mineral contentof the material discussed above.

Also, after temperature treatment at 500° C. or 750° C. (samples 4 and5), the inventive material was subjected to X-ray diffraction analysis.The results revealed a material comprising mainly plagioclase feldsparand traces of mica. Kaolinite and serpentine were also believed to bepresent but did not appear on the charts since these compounds releasetheir crystallization water when heated.

Also, ICP and DC plasma analyses on a sample of the inventive materialfurther detected the presence of the following elements, beyond thosealready noted in Table 1 above, in trace amounts in the material (on theorder of 0.5 ppm to 0.02% by weight for each element): Silver,molybdenum, nickel, tin, lithium, gallium, lanthanum, tantalum,strontium, zirconium, and sulfur. In addition, the presence of thefollowing oxides was confirmed: silica (SiO₂), titanium dioxide (TiO₂),alumina (Al₂ O₃), iron oxide as Fe₂ O₃ (magnetite), manganese oxide(MnO), magnesium oxide (MgO), calcium oxide (CaO), sodium oxide (Na₂ O),potassium oxide (K₂ O), and phosphorous oxide (P₂ O₅).

Another aspect of the present invention is the discovery that theinventive material can be used as a catalyst in at least two differentstates. For instance, the inventive material can be used in its nativestate or, alternatively, the inventive material can be combined with asuitable metal and subjected to conventional foundry furnace processingat appropriate temperatures, e.g., approximately 2000°-4000° F., to forma solid metal alloy variation of the inventive material. This materialis referred to herein as the "catalytic alloy material."

In either practical variation, the inventive material can be subjectedto magnetic separation treatment to remove magnetite, in the main,before use of the material as a catalyst in its native state or afterthe foundry treatment to form an alloy. The magnetic separationtreatment can be performed with a conventional ferromagnetic device or aconventional electromagnetic device.

The invention is first illustrated in greater detail herein withexemplary usage of the inventive material in its native state(preferably after agglomerated clumps are mechanically eliminated),followed by a more detailed discussion of the catalytic alloy material.

As another important aspect of the present invention, it has beendetermined that the inventive material of the present invention exhibitsits unexpected catalytic effect after being activated by heating to andmaintaining a temperature of approximately 850° F. or higher. However,this activation can be accomplished in-situ (in the automobile exhaustsystem) if the activating temperature of approximately 850° F. or higheris experienced by the emission control device as installed in the hotexhaust system.

On the other hand, if the exhaust system does not operate continually atthe activating temperature, then external heating sources, described ingreater detail hereinafter, may be used to provide the supplementalheating needed for activating the inventive material in the installedemission control device.

Unlike conventional honeycomb systems with platinum or palladium, themineral substance of the present invention will not clog up a honeycombsurface so as to necessitate replacements of the converter after a givenperiod of usage.

Also, and significantly, the inventive material or alloy substance ofthe present invention does not become deactivated or poisoned due toexposure to exhaust contaminates such as lead. Therefore, the inventivematerial of the present invention is particularly useful for catalytictreatment of combusted leaded gasoline.

Moreover, the nature of the inventive compound or alloy compound of thepresent invention allows for applications to be cast, shaped, and/orfabricated into any desired configuration commensurate with the specificusage, such as car exhaust manifolds, and coal burning smokestacks andstoves requiring customized designs of the emission control device.

Additionally, it has been determined that the catalytic effect of theinventive material of the present invention is demonstrated in itsnative state, but this catalytic effect also can be significantlyenhanced after subjecting the original inventive material to a magneticseparation treatment. During the magnetic separation, the black fractionof the material is taken out which mainly comprises magnetite (Fe₃ O₄ orFeO.Fe₂ O₃). The magnetic fraction may also contain hydroxylapatite--Ca₅(PO₄)₃ OH.

When heated to 220° C. in oxygen, the inventive material remaining aftermagnetical separation changes in color to red Fe₂ O₃ without, however,any noticeable change in magnetism or the X-ray structure pattern, butwhen heated further to 550° C., all magnetism disappears. This loss ofmagnetism is believed to be associated with the color change observed inthe material during heating at the higher operating temperatures of 850°F. or higher.

While the inventive material of the present invention has many anddiverse possible applications, as suggested above, the use of theinventive material in an emission control device inserted in an exhaustmanifold output of an internal combustion engine is described in detailbelow for illustration purposes.

It has been discovered that an emission control device containing theinventive material of the present invention, when inserted into theexhaust system of a gasoline engine, will reduce the harmful emissionsof hydrocarbons, carbon monoxide and carbon dioxide by as much as 72% ofthe original content. Moreover, a reduction in the NO_(x) emissions isobserved concomitant with an increase in the emission of oxygen (O₂).

An illustrative depiction of the emission control device, as to beinstalled, is provided in FIG. 1. The elements depicted in FIG. 1 aredescribed below by reference to their assigned reference numerals.

1 tail pipe

2 Retaining ring

3 Seal

4 Self-locking nut

5 Clamp

6 Clamp belt

7 Silencer

8 Seal

9 Air inlet hose

10 Hose clip

11 Grommet

12 Connecting pipe

13 Gasket-pre-heater pipe (left)

14 Gasket-pre-heater pipe (right)

15 Gasket-exhaust pipe flange

16 Self-locking nut

17 Clamp

18 Heat exchanger

19 Bolt

20 Pin

21 Circlip

22 Heater cable link

23 Pin

24 Clamp washer

25 Heater flap lever (left)

26 Lever return spring (left)

27 Emission Control Device (E.C.D.)

The E.C.D. insert device 27 can be installed without the need formodification of the existing engine exhaust system. However, atmosphericair must be prevented from entering the manifold before the emissioncontrol device (E.C.D.). All connections must be sealed.

In order to achieve satisfactory operating efficiency of the E.C.D., theoptimum exhaust gas temperature is 850° F. or above. The temperature ismeasured at the base of the E.C.D. In cold engine starting, and in someengines when idling, the exhaust gas temperature is below 850° F., sowhen this occurs, an external thermostat-controlled preheater device(not depicted) is attached to the E.C.D. For instance, a heating wire(not depicted) is connected between the E.C.D. and a remote thermostat.The heating wire is preferably coated with inventive material using thesame type of paste employed in the E.C.D. and described hereinafter.

When using the preheater device, the E.C.D. begins to function withinone minute of a cold engine start. When the engine exhaust gastemperature rises to 850° F. the thermostat automatically turns off thepreheater and remains off unless the temperature falls below 850° F. Thepreheater can be powered by the existing vehicle battery and produces anamperage load approximately equal to a factory installed cigarettelighter. Activation of the preheater can be accomplished through theaccessory section of the ignition switch, so there is no battery currentdrain until the engine is started.

In the event E.P.A. regulations change to include cold engine starting,the E.C.D. can simply be controlled in a similar manner as adapted fromknown diesel engine preheaters for cold starting in current use.

As depicted in FIG. 1, the E.C.D. 27 is tubular in construction or,alternatively, of strip construction, and is mounted in a standardexhaust manifold to tail pipe flange. The tube section O.D. isdetermined by the I.D. of the exhaust manifold opening. Since themanifold port inside diameter is greater than the exhaust tail pipeI.D., the device may be inserted into the manifold without creatingexhaust back pressure.

The tube portion of the E.C.D. may be steel or steel alloy or a ceramic.The tube is attached to a standard exhaust pipe flange that boltsdirectly to the manifold. When the device is installed, the tube portioninserts into the manifold and the flange is sandwiched between themanifold and the exhaust tail pipe flange. The preheater electricalconductor protrudes through, but is insulated from the flange, andconnects directly to the thermostat.

Since the tube acts only as a carrier for the reactive coating, thecomposition of the tube carrier need only be selected with theconstraint that it is able to withstand the high temperature of theexhaust gas and the operating temperature of the E.C.D. In this regard,high temperature ceramic tubes are useful.

The active ingredient of the E.C.D. is a coating containing theinventive material as applied to the tube surface portions, both insideand outside, and also onto the preheater wire, if needed.

In order to provide this coating, the inventive material described aboveis first dry pulverized to powder size of no less than 40 mesh butsufficient to eliminate clumps. Then the inventive mineral material isapplied to the surface of the E.C.D. tube in a dispersed state in a hightemperature ceramic paste, then cured in an oven at elevatedtemperature. A representative ceramic paste is Zirconia Ultra Hi-TempCeramic supplied by CoTronics Corp. This paste can withstand heat of upto 4000° F.

Installation of the Emission Control Device can be accomplished by theprocedure of placing the vehicle on a hoist, removing themanifold-to-tail pipe bolts, lowering of the pipe approximately threeinches. Then, the tube portion of the E.C.D. is inserted into theexhaust manifold, then the flange is aligned with the manifold bolt, andthen the tail pipe is replaced and the manifold bolt tightened.

On 2-4 and 6-cylinder engines having one exhaust manifold, one E.C.D.typically is used. On a V6 and V8 engines, the E.C.D. is inserted ineach manifold.

The basic shape of the device can be maintained for all engines, but thesize is determined by the cubic inch displacement of the engine.Approximately five flanges and tube sizes will fit U.S. vehicles andsome foreign vehicles. The emission control device of the presentinvention can be used alone as a catalytic converter for the exhaustsystem of a gasoline engine or, more desirably, can be used to augmentexisting exhaust systems.

When installed in older vehicles and any four cycle gasoline engines,the emission control device of the present invention acts as a catalyticconverter transforming the engine into a clean emission engine whichmeets current state emission standards. Also, while automotivemanufacturers have different exhaust configurations, the emissioncontrol device of the present invention can be adapted to physically fitthe different engine exhaust pipes in ready fashion. Nonetheless, theoperating efficiency of the emission control device of the presentinvention remains the same.

FIG. 2 shows another preferred embodiment for the E.C.D. FIG. 2generally depicts a two-cycle engine pulse air system. Numeral 30illustrates the connection to the cylinder head exhaust. E.C.D. 35 isretrofitted into the existing exhaust pipe 36. The cut-away part of theexhaust pipe 37 connects to the muffler. As shown, a tubular typeE.C.D., similar to that described in FIG. 1 above, is inserted in theexhaust pipe 36 below air tube 38 connecting to chamber 34. The basicconstruction and operation of a two-cycle engine pulse air system wouldbe well understood by one of ordinary skill in the art, FIG. 2 beingillustrative and showing other conventional components such as igniter 6volt @3 amp 33, pulse air intake 31, and pulse air valve 32. The tubeportion of E.C.D. 35 may be steel, steel alloy, or ceramic, similar inconstruction and operation to that described above with reference toFIG. 1. Again, the tube portion acts only as a carrier for the reactivecoating which contains the inventive material, preferably applied to thetube surface portions both inside and outside as a ceramic paste.Alternatively, the reactive coating may be the catalytic alloy materialwhich is described in more detail hereafter. The alloy version can beapplied, for example, by dipping the carrier in molten alloy andallowing the alloy to solidify on the desired surfaces.

FIG. 3 represents a perspective view of an internal combustion engine40, which would be understood to include 4-, 6-, and 8-cylinder enginesin widespread usage today. The construction and operation of suchinternal combustion engines, designed primarily for automotive vehicles,are well known and understood by one of ordinary skill in the art. InFIG. 3, combustion exhaust gases exit the engine through exhaust ports41, then through exhaust manifold 42, exhaust manifold outlet 43,through exhaust pipe 44, exhaust muffler 45, and exit through tailpipe46 in a known manner. In accordance with a preferred embodiment of thepresent invention, the inventive material, in either its raw materialform or the catalytic alloy material form described in more detailhereafter, can be used to reduce noxious emissions in a number oflocations. For example, an E.C.D. 51 showing the reactive coating 52 canbe inserted into the manifold at the cylinder head exhaust ports. TheE.C.D. is similar in construction and operation to that described abovewith respect to FIGS. 1 and 2. Also, an E.C.D. 51 can be adapted to beinserted into the exhaust manifold through flange portion 50, i.e.,sandwiched between the manifold 42 and the exhaust pipe flange 50 at theexhaust manifold outlet 43. Still further, an E.C.D. can take the formof that depicted as 52, which is an expanded tube designed to beinstalled inline in the exhaust pipe 44. A section of the exhaust pipeis cut out and the E.C.D. installed by use of standard exhaust pipeclamps or by welding. If desired, this E.C.D. 52 may be adapted tocontain a preheater 48 and thermostat 49, the thermostat beingcontrolled by the accessory side of the ignition switch. The rawinventive material, or the catalytic alloy variation described infurther detail below, is coated (see 52) on the interior diameter of thetube section and may also be coated on the preheater coil. An alloyE.C.D. 53 in the shape of a bolt can be inserted directly into theexhaust pipe 44 at any location, but preferably between the exhaustmanifold outlet 43 and muffler 45 as shown in FIG. 3.

As can be appreciated from the descriptions provided herein, thecatalytic device and inventive material of the present invention providean improved catalytic material which is highly resistant to poisoningfrom exhaust contaminants and has versatility in treating a widediversity of combustion gas material generated from, for example, solid(e.g. coal) and liquid fossil fuels, other carbonaceous materials suchas wood and garbage, as well as used tire rubber.

As noted above, the applicant has further discovered that the inventivematerial can be used as a catalyst in at least two different states. Forinstance, the inventive material can be used in its native state or,alternatively, the inventive material can be combined with a suitablemetal and subjected to foundry furnace processing to form a solid metalalloy variation of the inventive material.

Like the raw mineral variation, the alloy variation of the inventivematerial reacts on the exhaust gases in a similar manner as does otherproven catalytic converters with the following advantages.

The catalytic alloy material requires no additional chemicalcompositions, such as platinum sprays, impregnated materials applied toacrylics, or aluminum bodies, to create the catalysis reactions. Withthe density and the solid mass techniques, the catalytic alloy material,unlike the honeycomb systems used, will not clog up the honeycombsurface resulting in a need to replace the converter after a givenperiod of usage. The resulting catalytic alloy material is cheaper tomanufacture and install, offering a consumer a viable alternative atless cost.

In view of the non-clogging and reaction mass offered in the catalyticalloy material, it successfully reacts in treatment ofexhaust/combustion gases associated with coal burning, autos, garbageincineration, industrial coal applications, tire incineration, and wasteproduct removal. The catalytic alloy material can be developed withpre-heating capabilities either by induction or resistant methods tofacilitate its use at low temperatures. The catalytic alloy material canalso be added to some types of fuels for use in exhaust systems.

To form the desired catalytic alloy material, the inventive material, inits native state or having had magnetite removed, is mixed with asuitable metal. The raw inventive mineral material is first crushed, forexample, with a standard ore crusher. The selected metal is then heatedto a desired melting temperature, usually within the range of2000°-4000° F. for most metals; typically, the metal is melted in afurnace crucible. The crushed raw material may then be added to themolten metal. While this sequence is preferred, it will be understoodthat the metal and crushed raw material can be mixed together, thenheated, if desired. Examples of suitable metals include copper, iron,steel, stainless steel, brass, titanium, cast iron, aluminum, magnesium,etc. Of course, alloys of these and other metals can be chosen, ifdesired, depending on the ultimate end use of the catalytic alloymaterial. In general, the amounts of mineral component and metal,respectively, are not critical. Amounts of raw material as low as about1% by weight may be suitable for some applications. Preferred relativeproportions are preferably from about 10 to about 75 wt % inventivematerial and from about 90 to about 25 wt % metal. The applicant hasfound that the optimal effects of the invention will be achieved withvarying amounts of raw material/metal. Samples have been made using aratio of about 30 wt % copper/70 wt % raw material, 50 wt % titanium/50wt % raw material, 50 wt % aluminum/50 wt % raw material, 75 wt %stainless steel/25% wt % raw material, and 30 wt % brass/70 wt % rawmaterial. For automobile applications, these alloys have been found toexhibit excellent catalytic effects as to reducing pollutants in theexhaust gases while increasing the O₂ content of the catalyticallytreated exhaust in the manner described above.

The inventive material and the metal are combined together, as describedabove, to form a mixture. The mixture is then subjected to conventionalfoundry furnace processing to form a solid metal alloy compound.Typically, furnace temperatures are preferably from about 2000° to 4000°F., depending on the metal used. For example, a temperature range of2200-2400 works well for copper. On the other hand, stainless steel isknown to melt at higher temperatures. The appropriate meltingtemperatures and times would be readily apparent to one of ordinaryskill in the art. An average processing time in the furnace is about 1/2to 4 hours, after which the alloy material can be cast or molded intodesired configurations or solidified and re-melted later.

A solidified catalytic alloy material can be re-melted by appropriatelyheating it. Ceramic, metal, or wire configurations, which are pre-shapedor designed, can be dipped into or plated with the re-melted catalyticalloy material. Solid alloy devices can be cast, shaped, or fabricatedto any desired configuration, for catalyst uses such as combustibleapplications, fire boxes, or stacks.

The catalytic alloy material can be used in some exhaust applicationswhen the ceramic paste material version (discussed above with respect tothe E.C.D. in FIG. 1) may be unsuitable. The catalytic alloy materialcan be ground to a very fine mesh and then can be flame coated (using acommercial unit) on the substrate. The alloy material is applied with atorch-like device which sprays onto preformed units or devices.

In furnace and stove catalytic applications, the catalytic alloymaterial should be located just beyond the flames and maintained at 850°F. or higher for best results. The alloy can also be heated and used toremove harmful gases (such as H₂ S) in water in steam-well generatingplants. The catalytic alloy material can also be used to clean up toxicmaterial.

The inventive material in its native or alloy states can also be used ininsulation applications, extinguishing of fires, or in the cleanup andremoval of oil and fuel spills on land or water.

Both the alloy and the native material can be used as a catalyst in aself-contained burner, furnace, or incinerator whether in private orcommercial applications. The exhaust stack is piped back into the airfeed or fire box areas, or the exhaust of combination engines is pipedback into intake areas or carburetor areas. In this case, a closedsystem is obtained with no exhaust emissions. Fuels such as all fossilfuels, garbage, wood, plastics, tires, coal, or any material organic orinorganic which is combustible can have a self-contained system with noemissions.

While the invention has been described in detail and with reference to aspecific embodiment thereof, it will be apparent to one skilled in theart that various changes and modifications can be made therein withoutdeparting from the spirit and scope thereof.

What is claimed is:
 1. A catalytic alloy material comprising a mixtureof a mineral component and a metal, said mineral component comprisingplagioclase feldspar in an amount greater than 50 wt % based on theweight of the mineral component, said feldspar mainly comprising albiteand anorthite minerals.
 2. The catalytic alloy material as claimed inclaim 1, wherein said mineral component further comprises a minorproportion of mica, kaolinite and serpentine in a total amount of lessthan 50 wt % based on the weight of the mineral component.
 3. Thecatalytic alloy material as claimed in claim 1, wherein said metal isselected from the group consisting of copper, iron, steel, stainlesssteel, brass, titanium, cast iron, aluminum and magnesium.
 4. Thecatalytic alloy material as claimed in claim 1, wherein said mineralcomponent is used in an amount of from about 10 to about 75 wt %, andsaid metal is used in an amount of from about 90 to about 25 wt %. 5.The catalytic alloy material as claimed in claim 1, wherein said mineralcomponent contains magnetite.
 6. The catalytic alloy material as claimedin claim 1, wherein magnetite has been removed from said mineralcomponent.
 7. A catalytic alloy material produced by mixing a mineralcomponent with a metal and heating a resulting mixture to form an alloymaterial, said mineral component comprising plagioclase feldspar in anamount greater than 50 wt % based on the weight of the mineralcomponent, said feldspar mainly comprising albite and anorthitematerials.
 8. The catalytic alloy material as claimed in claim 7,wherein said mineral component further comprises a minor proportion ofmica, kaolinite and serpentine in a total amount of less than 50 wt %based on the weight of the total mineral component.
 9. The catalyticalloy material as claimed in claim 7, wherein said metal is selectedfrom the group consisting of copper, iron, steel, stainless steel,brass, titanium, cast iron, aluminum and magnesium.
 10. The catalyticalloy material as claimed in claim 7, wherein said mineral component isused in an amount of from about 10 to about 75 wt %, and said metal isused in an amount of from about 90 to about 25 wt %.
 11. The catalyticalloy material as claimed in claim 7, wherein said mineral componentcontains magnetite.
 12. The catalytic alloy material as claimed in claim7, wherein magnetite has been removed from said mineral component. 13.An emission control device comprising a substrate supporting a catalyticalloy material comprising a mixture of a mineral component and a metal,said mineral component comprising plagioclase feldspar in an amountgreater than 50 wt % based on the weight of the mineral component, saidfeldspar mainly comprising albite and anorthite minerals.
 14. Theemission control device as claimed in claim 13, wherein said mineralcomponent further comprises a minor proportion of mica, kaolinite andserpentine in a total amount of less than 50 wt % based on the weight ofthe mineral component.
 15. The emission control device as claimed inclaim 13, wherein said metal is selected from the group consisting ofcopper, iron, steel, stainless steel, brass, titanium, cast iron,aluminum and magnesium.
 16. The emission control device as claimed inclaim 13, wherein said mineral component is used in an amount of fromabout 10 to about 75 wt %, and said metal is used in an amount of fromabout 90 to about 25 wt %.
 17. The emission control device as claimed inclaim 13, wherein said mineral component contains magnetite.
 18. Theemission control device as claimed in claim 13, wherein magnetite hasbeen removed from said mineral component.
 19. An emission control devicecomprising a substrate supporting a catalytic alloy material comprisinga mixture of a mineral component and a metal, said mineral componentcomprising plagioclase feldspar in an amount greater than 50 wt % basedon the weight of the mineral component, said feldspar mainly comprisingalbite and anorthite minerals.
 20. The emission control device asclaimed in claim 19, wherein said mineral component further comprises aminor proportion of mica, kaolinite and serpentine in a total amount ofless than 50 wt % based on the weight of the mineral component.
 21. Theemission control device as claimed in claim 19, wherein said metal isselected from the group consisting of copper, iron, steel, stainlesssteel, brass, titanium, cast iron, aluminum and magnesium.
 22. Theemission control device as claimed in claim 19, wherein said mineralcomponent is used in an amount of from about 10 to about 75 wt %, andsaid metal is used in an amount of from about 90 to about 25 wt %. 23.The emission control device as claimed in claim 19, wherein said mineralcomponent contains magnetite.
 24. The emission control device as claimedin claim 19, wherein magnetite has been removed from said mineralcomponent.